Light reflector



May 30, 1933.

R. w. LUCE Er A1. 1,911,198

LIGHT REFLECTOR Filed Sept. 5, 1929 M HIM Afro/Wvg):

4f y ma@ WM Patented May 30, 1932?` UNITED STATES PATENT oFFlcE RICH-ABD W. LUCE, OF IOUNTAIN'SIDE; LESLIE I. MERRILL, OF IADISON', N'EW JERSEY, ASSIGNOBS T0 AMERICAN GASACCUHULATOB COMPANY, OF ELIZABETH, I NEW JERSEY', A CORPORATION 0F NEW JERSEY LIGHT RELECTOB 'Application med September 5, 1929. Serial No. 390,480.

Our invention relates to` light reflectors of a character adapted for use as'aids` to trallic upon highways, streets, and the like. Light reflectors embod ing our invention are oi 5 a character whic ts them for use not only as stationary signs or signals upon highways and streets but also for use upon automobiles and other like vehicles. They may be used, for example, in the construction 31@ of reectors for use upon the rear ends of automobiles, the front ends or other parts thereof.

The general object of theinvention is to provide a light reilector having means i5 whereby when it is employed in combination with a condensing lens it is edective as a signal for the aid of traiic whether it be located a relatively great distance from a source of light (such as the head-lights :3o of an automobile) or a relatively short dis tance therefrom or whether the source of light be located directly in iront of the reidector or on one side or the other oi the extension ofi the axial line of the 'retlecton ne 'lhis is oi especial advantage when the signs are employed as stationary signals upon highways where it is necessary that they be located in adjoining relation to the highway upon one side or the other thereof. llt will So be apparent that as the lights oi an automobile approach nearer to the sign the angles between the rays or@ light which radi ate from the lights upon the automobile and which impinge upon the redector and the central axis ci the redactor increase, so that, unless means is provided tor causing an increased or relatively wide dispersion oli the reflected rays oi light, the presence oi the sign or signal will not be apparent to persons in the automobile.

il. further object ot the invention is to provide a light reilector having concentric circular light-redecting areas, the surface oi one circular area being located in displaced relation, ront or back, with respect to the euri-'ace of the other concentric lightredecting area.

Adurther object of the invention is to prov-ide a method novel in character by which a redector embodying the above in-l tured expeditiously dicated `characteristics may be manufacand at a minimum of expense.

Without undertaking to explain more fully or at greater length the various objects and advantages of our invention we shall now proceed with a detailed description thereof wherein other-objects and advantages thereoi either will be 'especially referred to or else will become apparent.

In order that the invention may be readily understood and its advantages from a practical standpoint full appreciated, reference should be made to the accompanying drawing, wherein we have illustrated a completed redector embodying our invention and wherein also we have illustrated the method by which the same may be pro duced.

ln the drawing,

Fig. l is a view in edge elevation of a section of thin sheet metal which may be employed in the manufacture of the reflector;

Fig. 2 is a view in Sectional elevation of a die structure by means of which initial for- 75 mation of the reflector is e'ected;

Fig. 3 is a top plan view of a section of a strip such as is illustrated in Fig. l follow ing the operation illustrated in F ig. 2;

Fig. l is a longitudinal sectional view of @3 plie partially `formed redectors shown in nig. 3;

llligs. 5, ti, and are transverse sectional views, respectively, of portions of a partially coinpleted reflector, indicatin certain S5 steps o the process employed in t e manufacture of the redectors;

Fig. 8 is a vertical longitudinalsectional view of press including dies by which the .'nal forming operation in the production 19@ of a redector is edected;

llig. 9 is an enlarged view of a fragmentary portion of the completed reflector;

Fig. l() is a view of the reflector after the operation indicated in llig. 8; and

Fig. ll is a view in central vertical longitudinal section of a redactor embodying the invention.

lt may be stated that while the reflector as illustrated in Fig. ll is complete in so Mm far as its reflecting qualities and characteristics are concerned, and rays of light which may impinge upon the concentrlcally arranged reflectin surfaces at the bottom of the reflector as s own in Fig. 11 are refiected thereby, yet, in actual practice it is customary and perhaps necessary to combine with the said reflector a condensing lens of ball or other form of suitable material through which the impinging and reflected rays of light are adapted to pass in known manner.

In the production of reflectorsembodying our invention we employ preferably long strips of suitable sheet metal, such as copr, a section of which-is shown at 1 in ig. 1. Stri s of this character are supplied lto andJ fed successively through a punch and die press, as indicated in Fig. 2, comprising a stationary member 2, the upper side of which is provided with a recess 3 which is circular in cross section and may be of a depth substantially as shown. The member 2 1s also provided with an opening 3 of a shape such as that of the opening shownl in the metal strip, as illustrated in Fig. 3. The forming punch member of the unch and die structure is shown at 4 with 1ts lower end projecting into the recess 3. The said forming punch member 4 is carried up on a head 5 of a reciprocatable member 6. The head 5 also supports in spaced relation to the forming'punch 4 a cutting punch or element 7, located in alignment with the opening 3 in the stationary memf ber2, and of the same shape in cross section as that of the said opening but with dimensions slightly less than those of the said opening so that it may enter the same as indicated. A draw plate 8 is also carried by the head 5, being supported upon the lower ends of rods 9, the upper ends of which extend through openings 10 provided in the said head. The said upper ends terminate in heads 11 which are located in openings 12, rovided in the upper side of the head 5. prings 13 are coiled about the rods 9. The lower ends of said springs are seated against the upper side of the draw plate 8 while the upper endslthereof are seated against the head 5. The said springs tend to expand and such tendency operates to hold or tend to hold the draw plate 8 in its farthest position away from the head 5 with the heads 11 resting upon the bottom of the openings 12. y

As has .been stated already, metal strips which are relatively narrow, as indicated 1n F'g. 3, are fed through the punch and die device of a structure such as is shown in Flgi 2, the feeding thereof being -from the rig t toward the left. Each strip is fed over the upper side of the member 2 and below the forming and cutting punches 4 and 7. Upon the descending movement of the head 5 the forming and cutting punches ings 16 the forming punch 4 descends and depresses the central portion of the metal of the strip between adjoining openings 16 to form cup-like portions 17 which are surrounded by relatively wide flanges 18. These flanges are connected together by the narrow connecting strips 19 at the oliposite edges of the structure, as shown in ig. 3. After the com letion of the operation, ias illustrated in 4` ig. 2 of the drawing, the portion 17 preferably is subjected first t0 an annealing treatment, after which it is pickled in known manner to remove the scale therefrom. In Fig. 5 ofthe drawin we have illustrated in section a portionio the initially formed cup-like p art, indicating by means' of alternate projections and depressions 20 and 21 the roughness of the surfaces of the metal. 'After the pickling operation the strip embodying the initially formed cup-like portions is subjected to a bright dipping treatment, which consists in the immersion of the same in a li uid bath including suitable chemicals. he piekling and bright dipping operations are quite common in methods or processes of this character and need-',-not be referred to or described in detail. It may be noted b reference to Fig. 6 that the result of the right dipping operation is to modify somewhat the the outer or apical portions thereof. After the bright dipping operation a ver thin plate or coatin of a suitable meta such as silver is app ied, preferably by electrochemical deposition upon both sides of the initial.cupl1ke structure. The presence of these silver coatings is indicated at 22 and 23 in Fig. 7 of the drawing. The same coatings are shown at 22 and 23 in Fig. 9 of the drawing after the initially formed cup-like portions have been subjected to the further pressing and forming operation indicated in Fig. 8 of the drawing.

In the structure as shown in Fig. 8 of the drawing we have provided a statlonary die member 25 terminating at its upper end in a projecting portion 26 of smaller diameter than the lower portion thereof. The diameter of the portion 26 will be goverenedby the desired diameter of the inner'portion 2 of the completed reector, while the diameter of the outer portion of the -member 25 will depend upon the desired diameter of the front portion 28 of the completed reeetor. The upper or innner end of the portion 26 is provided with a circular prorojections 20 by removingart.

jection 30. The annular surface 31 upon the outer portion of the proection 26 and also the outer surface 31 o the low projection 30 are spherical, so that the inner reflecting surfaces of the concentric portions 32 and 33 of the completed vreflector shown in Fig. 11 of the drawing are spherical. The upper reciprocatable portion 35 of the die is provided with a recess 36 the inner surface of which is the counterpart of the outer surfaces of the projecting portions 26 and 30 of the stationary die member 25. ln the operation ci the die press of Fig. 8 an initiall formed cup-shaped member comprising t e parts 17 and 13 is placed in position over the upper end oi the member 25, whereupon the female die member35 is moved downwardly so as to 'act upon and press the inne. or rear end portion ot the said cup-shaped member into form corresponding to the internal shape or configuration of the recess 36 in t e member 35 and the external conn ration or shape of the portions 23 and 30 or the die member 25.

A pressin and forming member 40 moves downward simultaneously with the member 35. The lower end portion of the member 40 is tubular, as indicated, and the inner edges of the lower end thereof contact with the outer portion of the lange 18 and bend the same downwardly, as indicated at 41, so as to form the outer or front portion 28 of the reflector of greater diameter than the inner or rear portion 27 thereof. rlhe member 40 constitutes a drawing and shaping member and operates in the manner which will be ap arent and clear to those skilled in the he lower end of the member 40 o crates to clamp the outer portion oi' the liange 18 against the upper side of a holding ring 42 which is supported upon springs 43 in the usual known manner. 1t will be noted that the portion 41 is bent around the curved edge of a shoulder 44 provided upon the member 25 and surrounding the lower end of the rojection 26.A The presence of this shoulder and the cooperation of the circular open end of the member 40 therewith results in the formation of a shoulder 45 in the completed reflector, as

-is shown in Fig. 11 of the drawing. In the downward movement of the member 40 the outer edge 46 of the lower end thereof cooperating withthe edge 47 of an opening 48 in the block 49 operates 'to sever, as indicated at 50, the narrow connections 19 to which reference has been made previously.

The member 35 of the die is mounted within the opening 54 in the lower end of the member 40 and is Amovable in the saidl opening axially thereot. The member 35 terminates at its upper end in an enlarged or head portion 55 the lower end ot which is tapered, as indicated at 56,- to term a tapered shoulder which is adapted tollen-l gage with a similarl tapered shoulder 57 provided interiorly o the hollow lower end of the member 40, as shown.

The upper end of the member 35 is provided with a projection 58 of relatively small diameter, which is adapted to contact at its upper end with the member 40 at the upper end of the opening 54'in the lower soi lin the operation of the die press shown in Fig. 8 the member 40 is moved downwardly by means of usual construction (not shown) provided for that purpose, and initially the spring 60 operates to transmit l pressure from the member 40 to the member 35 to cause the latter to act uponthe upper closed end portion of the reflector and press Vand draw the same so asito cause the inner .portion of the flange surrounding the initially "formed cup-like portion previously referred to to seat upon the shoulder 44.

Simultaneously the lower annular end portion of the member 40 contacts with the outer portion of the said ange and bends and draws the same around the outer edge of the shoulder 44 and presses the same against the portion of the member 25 ot larger diameter below the said shoulder 44. lt will be understood also that at the beginning of its action upon the outer portion of the said flange the connecting strips 19 are severed, as above described. J ust prior to the completion of the downward movement of themember 40 the upper end of the pro'ection 58 comes into contact with the sai member 40 at the upper end of the opening 54 therein, so that during the latter part of the operation of the dies the portions 32 and 33 of the reflector are subjected to high positively or unyieldingly eX- erted pressure, so that. a polish is imparted to the inner spherical surfaces thereof corresponding to the polish of the surfaces 31 and 31. During that period the pressing outwardly or rearwardly of the portion 32 of the reflector be ond the plane of the annular portion 33 tlsiereof is completed.

The spherical surfaces 31 and 31 have the same center, withA radii of Eifferent lengths. llt follows that the inner reflecting surfaces oit the corresponding portions 32 and 33 of the reflector also have the same center, with radii of diderent len hs'.1 From that arrangement it follows t at when the reilector ion is embodied in a device for use upon highl ways, streets and the like, and is combined with a condensing lens of ball or other form as above indicated and assumin that the incident rays of a beam of light rom a distant source focus upon the reflecting surface of the part 33, it will be apparent that the rays of a beam under like conditions which impinge upon the reflecting surface of the part 32 will be relatively widely dispersed, so that the beam which is reflected is in the shape of a widening cone. By this means the presence of the sign or signal is apparent' to persons who may occupy an automobile or the like not only when the the sign or signal is located a relatively great distance in front of the automobile but also after the automobile has reached a position quite near to the said sign or signal and occupies a position either directly in front of the reector or upon one side or the other of a line extendedv axially of the reflector.

The characteristic construction of the reflector, which when it is associated with a lens results in a relatively wide dispersion of the light which is reflected from the inner reflecting surface of the portion 32, is of especial value and advantage in cases where light reflecting ydevices are employed upon the rear ends of automobiles and the like or upon the fronts of automobiles either alone or in association with the usual tail and cowl lights and also when mounted upon stationary supports located upon or adjoining the edges of highways, streets and the like as aids to traflic. As a matter of fact, light reflecting devices of this character may be employed upon different parts of automobiles in order that knowled e may be given to approaching automobihsts of the presence of an automobile (or other structure) in the paths of such approaching automobiles. l It will be seen that by our invention We have provided a sign or si al consisting of a light reflector of simp e construction having means whereby it W1ll operate efliciently either when automobiles or the like are approaching the same and are located a relatively great distance therefrom or are located relatively near to the same or at an intermediate point or `position and eit er laterally or directly in front thereof. Having thus described our invention, what we claim and desire to secure by Letters Patent is:

1. A light reflector of sheet metal, com` ner surfaces of the central portion and the surounding annular portion being spherical and having a common center.

2. A hollow sheet metal light reflector having front and rear cylindrical wall portions, the diameter of the front wall portion being greater than that of the rear wall portion, the two portions being connected by a transversely extending portion constitutin an annular shoulder, the bottom of sai reflector comprising a central portion which projects beyond the plane of an annular portion which surrounds the said central ortion, the inner surfaces of said portions being spherical and light-reflecting.

3. A hollow sheet metal light reflector having front and rear cylindrical wall nortions, the diameter of the front wall portion being greater than that of the rear Wall portion, the two portions being connected by a transversely extending portion constituting an annular shoulder, the botton of said reflector comprising a central portion which projects beyond the plane of an annular portion which surrounds the said central portion, the inner surfaces of said portions being spherical and light-reflecting and having a common center.Y

4. A hollow sheet metal light reflector having front and rear cylindrical Wall portions, the diameter of the front wall portion being greater than that of the rear wall ortion, the two portions being connected y a transversely extending portion constituting an annular shoulder, the bottom of said reflector comprising central and annular zone ortions the inner surfaces thereof bein sp erical, and the radii of the surfaces oV the said portions being of different lengths.

In testimony that we claim the foregoing as our invention, we have hereunto signed our names this 30th day of August, A. D.,

RICHARD LUCE. LESLIE M. MERRILL. 

